Novel medical device conductor junctions

ABSTRACT

A method for making an elongate medical device includes coupling a conductive fitting to an elongate conductor and providing an opening through an insulative layer in proximity to the fitting in order to expose the fitting.

TECHNICAL FIELD

The present invention relates to elongated medical devices and more particularly to novel conductor junctions.

BACKGROUND

Cardiac stimulation systems commonly include a pulse-generating device, such as a pacemaker or implantable cardioverter/defibrillator that is electrically connected to the heart by at least one electrical lead. An electrical lead delivers electrical pulses from the pulse generator to the heart, stimulating the myocardial tissue via electrodes included on the lead. Furthermore, cardiac signals may be sensed by lead electrodes and conducted, via the lead, back to the device, which also monitors the electrical activity of the heart.

Medical electrical leads are typically constructed to have the lowest possible profile without compromising functional integrity, reliability and durability. Often junctions formed between a conductor and other components included in leads, for example electrodes, can increase the lead's profile, therefore it is desirable to develop low profile junctions.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the invention and therefore do not limit its scope, but are presented to assist in providing a proper understanding of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. The present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements, and:

FIG. 1 is a plan view of an exemplary medical electrical lead in which embodiments of the present invention may be incorporated;

FIGS. 2A-B are perspective views of portions of the exemplary lead according to embodiments of the present invention;

FIGS. 3A-B are plan views, each of a portion of a lead subassembly according to alternate embodiments of the present invention;

FIGS. 4A-C are schematics, each showing a step of an assembly method according to alternate embodiments of the present invention;

FIG. 4D is a section view of a lead assembly according to one embodiment of the present invention;

FIGS. 5A-B are section views showing steps of assembly methods according to alternate embodiments of the present invention;

FIG. 6 is a section view showing a step of an assembly method according to an alternate embodiment of the present invention;

FIG. 7A is a plan view of a portion of a lead according to one embodiment of the present invention;

FIG. 7B is a section view of a segment of the portion of the lead shown in FIG. 7A;

FIG. 7C is a plan view of a lead according to another embodiment of the present invention;

FIG. 7D is a section view of a lead according to yet another embodiment of the present invention;

FIG. 8A is a plan view of a lead subassembly according to one embodiment of the present invention;

FIG. 8B is a section view of a lead assembly according to another embodiment of the present invention; and

FIG. 9 is a perspective view of an alternate embodiment of a portion of a lead subassembly.

DETAILED DESCRIPTION

The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides a practical illustration for implementing exemplary embodiments of the invention.

FIG. 1 is a plan view of an exemplary medical electrical lead 100 in which embodiments of the present invention may be incorporated. FIG. 1 illustrates lead 100 including a lead body 10 extending distally from a transition sleeve 20 to a distal end, which includes an electrode tip 16, tines 18 and an electrode ring 14; a defibrillation coil 12 extends along a portion of lead body 10 in proximity to the distal end. FIG. 1 further illustrates connector legs 22 and 24, which are adapted to couple lead to a medical device according to means well known to those skilled in the art, extending proximally from transition sleeve 20; conductors (not shown) extending through lead body 10, transition sleeve 20 and legs 24, 22 couple electrodes 16, 14 and 12 to connector contacts 36, 32 and 30, respectively, of connector legs 24 and 22. Embodiments of the present invention include means for coupling electrodes mounted about a lead body, for example defibrillation coil 12 or electrode ring 14, to a conductive wire or cable extending within the lead body.

FIGS. 2A-B are perspective views of portions of the exemplary lead according to embodiments of the present invention. Via cut-away views, FIG. 2A illustrates lead body 10 including an inner elongate structure 201 about which a first conductor 202 and a second conductor 204 are positioned; a first conductive fitting 220 and a second conductive fitting 240 are coupled to first and second conductors 202 and 204, respectively. According to the illustrated embodiment, elongate structure 201 includes a lumen 205 in which an inner conductor 250 extends. According to an exemplary embodiment of the present invention lumen 205 has a diameter between approximately 0.01 and 0.03 inches. Using dashed lines, FIG. 2A further illustrates the extension of an outer insulative layer 210 over the subassembly, a first electrode 112 and a second electrode 114 coupled to conductors 202 and 204 via fittings 220 and 240, respectively, and a distal end of lead body 10 terminated by electrode tip 16, which is coupled to inner conductor 250, and tines 18. According to embodiments of the present invention at least first conductive fitting 220 is coupled to conductor 202, before covering the subassembly (formed, as illustrated, of inner elongate structure 201, conductors 202, 204 and fitting 202) with outer insulative layer 210. FIG. 2B illustrates a portion of lead body 10, according to one embodiment, before electrodes are coupled.

FIG. 2B further illustrates conductors 202, 204 each comprising a cable 222, 224, formed of a plurality of conductive wires bundled together, and an outer insulative layer 212, 214. According to alternate embodiments, conductors are each formed of a single wire; furthermore, although conductors 202 and 204 are shown wrapped or wound about inner elongate structure 201 in FIG. 2A, conductors 202 and 204 according to alternate embodiments can be positioned approximately linearly along inner elongate structure 201. An example of an appropriate material for conductor wires employed by embodiments of the present invention is an MP35N alloy; one or more conductor wires may further include a low resistance core, for example silver. An example of an appropriate material for insulative layers 212, 214 is ETFE, which may be formed as a jacket extruded about cables 222, 224 prior to positioning conductors 202, 204 along structure 201. According to some embodiments of the present invention, elongate structure 201 is formed from an insulative material, examples of which include fluoropolymers, silicones, and polyurethanes. It should be noted that when conductors 202, 204 are positioned along structure 201 they can be embedded in an outer surface of structure 201 according to some embodiments.

FIGS. 3A-B are plan views, each of a portion of a lead subassembly according to alternate embodiments of the present invention. FIG. 3A illustrates a subassembly of elongate structure 201 on which a conductor 302 including a conductive fitting 320 coupled thereto is positioned; according to this embodiment, conductive fitting 320 is coupled to conductor 302 prior to positioning conductor on elongate structure 201. FIG. 3B illustrates conductive fitting 220 being directed, per arrow A, toward a portion of conductor 202 where insulative layer 212 has been removed to expose cable 222 in order to couple fitting 220 to conductor 202; according to this alternate embodiment, fitting 220 is coupled to conductor 202 after conductors 202 and 204 have been positioned on structure 201. It should be noted that although FIG. 3B shows insulative layer 212 removed for coupling with fitting 220, other types of fittings having internal features to penetrate layer 212 may be employed so that layer 212 need not be removed for coupling. Furthermore, according to other embodiments of the present invention a fitting is coupled to a conductor, for example fitting 220 of conductor 202 (FIG. 2A), before an outer insulative layer, for example outer insulative layer 212 about cable 222 (FIG. 2B), is formed. According to these embodiments, the conductor and fitting are covered with an outer insulative layer, which is subsequently removed in proximity to the fitting, either before positioning the conductor including the fitting on elongate structure 201 or afterwards, and may be in conjunction with providing an opening in outer insulative layer 210. Means for removing the insulation in proximity to the fitting are well known to those skilled in the art and include but are not limited to, mechanical and laser stripping.

FIGS. 4A-C are schematics, each showing a step of an assembly method according to alternate embodiments of the present invention. FIG. 4A illustrates the subassembly shown in FIG. 3A directed, per arrow B, toward a lumen 405 of an outer insulative layer 410; according to this embodiment of the present invention, outer insulative layer 410 is formed as a generally tubular structure and the subassembly is inserted therein. FIG. 4B illustrates the subassembly shown in FIG. 3B, after fitting 220 is coupled to conductor 202, positioned in proximity to an outer insulative layer 411; according this other embodiment, outer insulative layer 411 is initially formed as a sheet and is wrapped about the subassembly per arrows C and then bonded along a seam formed when opposing edges of layer 411 come together. Suitable materials for layers 410, 411 include, but are not limited to, silicones, polyurethanes and fluoropolymers.

FIG. 4C illustrates the subassembly shown in FIG. 3A about which an outer insulative layer 412 is being wrapped per arrow D. According to yet another embodiment of the present invention, outer insulative layer 412 is in the form of a tape which is wrapped about the subassembly to form a lead body, the longitudinal edges of the tape being bonded or sintered together during or following the wrapping process. An example of a wrapping process is described in International Publication Number WO 02/089909 in conjunction with FIGS. 4 and 5; FIGS. 4 and 5 of WO 02/089909 along with associated descriptions therein are incorporated by reference herein. Although WO 02/089909 describes the process for covering a defibrillation electrode with e-PTFE, the inventors contemplate using the process in conjunction with an insulative fluoropolymer material to form outer insulative layer 412 according to some embodiments of the present invention.

FIG. 4D is a section view of a lead assembly according to an embodiment of the present invention. FIG. 4D illustrates a conductor 402 and a conductive fitting 421 coupled thereto positioned along elongate structure 201, and an insulative layer 413 including an opening through which a protrusion 421 of conductive fitting 420 extends. According to one method of the present invention, layer 413 is applied as a coating, either by an extrusion or a dip process, and the opening is formed during the coating process by means of protrusion 421 of fitting 420 penetrating through the applied coating. Referring back to FIG. 4C, an alternate method for forming an opening for fitting 320 is to leave an opening or a gap in the wrap of insulative layer 412. Suitable materials for layer 413 include, but are not limited to, silicones, polyurethanes and fluoropolymers.

FIGS. 5A-B are section views showing steps of assembly methods according to alternate embodiments of the present invention. FIG. 5A illustrates a conductor 402 and a conductive fitting 520 coupled thereto positioned along elongate structure 201 and an insulative layer 413 formed thereover wherein a step to form an opening in proximity to fitting 520 is shown as arrow 500. According to one embodiment the opening is formed by mechanical cutting; according to another embodiment the opening is formed by ablation, i.e. laser; according to yet another embodiment an application of heat energy causing material flow forms the opening either independently or in conjunction with mechanical cutting. Means for forming the opening according to these embodiments are well known to those skilled in the art. FIG. 5B illustrates a subsequent step in an assembly method wherein, following the formation of the opening, fitting 520 is augmented with an attachment 530, which includes a protrusion 532 extending out through the opening to facilitate electrode coupling. According to the illustrated embodiment, attachment 530 further includes a portion 531 adapted for coupling with fitting 520, for example by welding, and a groove 533 adapted for coupling with an electrode, for example a filar of coil electrode 12 shown in FIG. 1. According to alternate embodiments, fitting 520 need not be augmented and an electrode includes an inwardly projecting feature to couple with fitting within or below opening; such embodiments are described in greater detail in conjunction with FIGS. 6 and 7D.

FIG. 6 is a section view showing a step of an assembly method according to an alternate embodiment of the present invention wherein forming an opening in proximity to a fitting is accomplished when an electrode is coupled to the fitting. FIG. 6 illustrates an electrode 642 mounted about a lead body formed by inner elongate structure 201, conductors 402, 404 positioned along the structure 201, conductive fitting 420 coupled to conductor 402 and insulative layer 510 formed thereover. FIG. 6 further illustrates electrode 642 including an internal feature 60 which is adapted to penetrate through layer 510 as a tooling head 650 is pressed against electrode 642 per arrow E; according to one embodiment, tooling head 650 is used for staking electrode 624 to fitting 520 and feature 60 penetrates by means of mechanical cutting; according to another embodiment tooling head 650 is used for resistance welding electrode 624 to fitting 520 by means of a current passed through head 650 and conductor 402 such that penetration is made via thermally assisted flow of material forming layer 510. Dashed lines in FIG. 6 illustrate a groove 525 which may be formed in fitting 520 and dimensioned to receive feature 60 of electrode as it is pressed inward; according to one embodiment groove 525 serves to facilitate the penetration of feature 60 through layer 510 which would be spread taught across groove during a previous assembly step.

FIG. 7A is a plan view of a portion of a lead according to one embodiment of the present invention and FIG. 7B is a section view of a segment of the portion of the lead shown in FIG. 7A. FIG. 7A illustrates electrode 72 mounted on lead body 10 and including a feature formed as a slot 70 into which a protruding portion of a fitting 720 is inserted for coupling, for example by laser welding. The section view of FIG. 7B further illustrates fitting 720 coupled to conductor 202 and the protruding portion of fitting 720 extending through an opening in outer insulative layer 210 to fit within slot 70 of electrode 72. FIG. 7C is a plan view of a lead according to another embodiment of the present invention wherein a protruding portion of fitting 720 includes an electrode surface 76 formed directly thereon, eliminating the need for an additional electrode component; as illustrated in FIG. 7C a plurality of fittings 720 may be positioned along a lead body 715 to provide multiple electrode surfaces 75.

FIG. 7D is a section view of a lead according to another embodiment of the present invention wherein a conductive fitting is inserted into an electrode feature for coupling. FIG. 7D illustrates an electrode 74 mounted on lead body 10 and including a hook-like feature 741 extending inward through the opening in outer insulative layer 210 to engage and couple with fitting 220, which is coupled to conductor 202. Hook-like feature 741 may be coupled to fitting 220 by means of crimping or laser welding.

FIG. 8A is a plan view of a lead subassembly according to one embodiment of the present invention and FIG. 8B is a section view of a lead subassembly according to another embodiment of the present invention wherein fittings include surfaces conforming to a contour of the subassemblies. FIG. 8A illustrates the subassembly including inner elongate structure 201, a first conductor 802, a second conductor 804 and a flexible fitting 820 coupled to first conductor 802. Flexible fitting 820 may be formed of a conductive polymer, examples of which include intrinsically conductive polymers, such as polyacetylene and polypyrrole, and conductor-filled polymers, such as silicone rubber having embedded metallic, carbon, or graphite particles; once formed fitting 820 may be assembled about conductor 802 into a close fitting relationship, i.e. an interference fit, or fitting 820 may be formed in situ about conductor 802, for example by a molding process. Examples of metallic conductors, which may be used for any of the fitting embodiments described herein include, but are not limited to, platinum, platinum-iridium alloys, stainless steel and titanium.

FIG. 8B illustrates the subassembly including inner elongate structure 201, first conductor 202, second conductor 204 and a fitting 820 coupled to conductor 202; fitting 820 includes a surface 851 conforming to a contour of structure 201 and a protrusion 852 extending from an opposite side of surface 851 out through the opening in layer 210. According to the embodiments illustrated in FIGS. 8A-B positioning of conductors 802 and 202 about structure 201, after the fittings are coupled to the conductors, may be facilitated by the conforming fittings.

FIG. 9 is a perspective view of an alternate embodiment of a portion of a lead subassembly including a cut-away cross-section and a partial longitudinal cut-away section. FIG. 9 illustrates a lead body 90 including an insulative layer 900 covering an elongate structure 901 formed by an insulated conductor about which additional insulated conductors 902, 904, 906, 908, 910 and 912 are wrapped; a conductive fitting 918 has been coupled to conductor 908 prior to covering the subassembly with insulative layer 900. As previously described for other embodiments of the present invention, conductive fitting 918 may be coupled to conductor 908 either before or after positioning conductor along elongate structure 901; an opening subsequently formed in layer 900, either during or after the covering process, will expose fitting 918 for electrode coupling.

In each of the above described embodiments the openings through which couplings are made between electrodes and conductor fittings may be sealed with an adhesive, for example silicone medical adhesive or polyurethane adhesive, to prevent fluid ingress; sealing may be performed either before or after the coupling depending upon the embodiment.

Finally, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited; numerous other embodiments and uses are intended to be encompassed by the claims attached hereto. For example a host of other types of medical devices including electrical mapping catheters, ablation catheters and neurological stimulation devices may employ embodiments of the present invention. 

1. A method for making an elongate medical device, the method comprising the steps of: coupling a conductive fitting to an elongate conductor; positioning the elongate conductor along an elongate structure; covering a subassembly comprising the conductor, conductive fitting and elongate structure with an insulative layer to form an elongate device body; and providing an opening through the insulative layer in proximity to the fitting in order to expose the fitting.
 2. The method of claim 1, wherein the fitting comprises a metal.
 3. The method of claim 1, wherein the fitting comprises a conductive polymer.
 4. The method of claim 1, wherein the fitting conforms to a contour of the subassembly.
 5. The method of claim 1, wherein the fitting includes a surface protruding outward through the opening.
 6. The method of claim 1, wherein the fitting includes an electrode surface exposed at the opening.
 7. The method of claim 1, wherein the elongate conductor comprises a wire.
 8. The method of claim 1, wherein the elongate conductor comprises a plurality of wires arranged side-by-side.
 9. The method of claim 1, wherein the elongate conductor comprises a cable formed from a plurality of wires bundled together.
 10. The method of claim 1, wherein the elongate structure is formed from a material comprising a polymer selected from the group consisting of polyurethane and silicone.
 11. The method of claim 1, wherein the elongate structure is formed from a material comprising a fluoropolymer.
 12. The method of claim 1, wherein the elongate structure includes a lumen extending therethrough along a length of the structure.
 13. The method of claim 12, wherein the lumen has diameter between approximately 0.01 inch and 0.03 inch.
 14. The method of claim 1, wherein the elongate structure comprises another conductor.
 15. The method of claim 1, wherein providing the opening comprises forming the opening by means of mechanical cutting.
 16. The method of claim 1, wherein providing the opening comprises forming the opening by means of ablation.
 17. The method of claim 1, wherein providing the opening comprises forming the opening by means of thermally assisted flow.
 18. The method of claim 1, wherein providing the opening comprises leaving the opening during the covering process.
 19. The method of claim 1, wherein providing the opening comprises penetrating through the layer during the covering process.
 20. The method of claim 19, wherein the fitting penetrates the layer.
 21. The method of claim 1, further comprising the steps of: coupling an electrode to the fitting; and mounting the electrode on the body.
 22. The method of claim 21, wherein coupling the electrode comprises inserting a portion of the fitting into a feature of the electrode.
 23. The method of claim 22, wherein the feature of the electrode extends through the opening beneath the layer when the electrode is mounted on the body.
 24. The method of claim 21, wherein the coupling step comprises a process selected from the group consisting of laser welding, resistance welding, crimping and staking.
 25. The method of claim 22, wherein the portion of the fitting protrudes outward through the opening.
 26. The method of claim 21, further comprising a step of augmenting the fitting to provide a portion protruding outward through the opening and wherein coupling the electrode comprises inserting a portion of the electrode into the protruding portion of the fitting.
 27. The method of claim 21, wherein coupling the electrode comprises inserting a portion of the electrode into a feature of the fitting.
 28. The method of claim 27, wherein the feature of the fitting protrudes outward through the opening.
 29. The method of claim 27, wherein the feature of the fitting comprises a groove.
 30. The method of claim 21, wherein providing the opening comprises penetrating through the layer during the electrode coupling process.
 31. The method of claim 30, wherein penetrating is by means of a feature included on the electrode.
 32. The method of claim 30, wherein penetration is by means of resistance welding energy.
 33. The method of claim 21, wherein the electrode has a ring form.
 34. The method of claim 21, wherein the electrode has a coil form.
 35. The method of claim 1, wherein covering the subassembly comprises inserting the subassembly into the insulative layer having a generally tubular form.
 36. The method of claim 1, wherein covering the subassembly comprises an extrusion process.
 37. The method of claim 1, wherein covering the subassembly comprises a dip-coating process.
 38. The method of claim 1, wherein covering the subassembly comprises wrapping the insulative layer around the subassembly.
 39. The method of claim 1, wherein the insulative layer comprises a material selected from the group consisting of polyurethane and silicone.
 40. The method of claim 1, wherein the insulative layer comprises a fluoropolymer.
 41. The method of claim 1, wherein a portion of the elongate conductor becomes embedded in the outer surface of the elongate structure by the positioning step.
 42. The method of claim 1, further comprising the step of forming an insulative layer over the elongated conductor prior to the positioning step.
 43. The method of claim 1, wherein the fitting is coupled to the elongate conductor prior to the positioning step.
 44. The method of claim 1, wherein the fitting is coupled to the elongate conductor after the positioning step.
 45. The method of claim 1, wherein the positioning step comprises winding the conductor around the elongate structure.
 46. A medical electrical lead, comprising: an inner assembly including an elongate inner structure, an elongate conductor extending along an outer surface of the elongate inner structure and a conductive fitting coupled to the elongate conductor; an outer insulative layer covering the inner assembly and including an opening in proximity to the fitting; and an electrode mounted about the outer insulative layer and including a feature extending inward through the opening to couple with the conductive fitting.
 47. The lead of claim 46, wherein the electrode feature penetrates the outer insulative layer to form the opening.
 48. The lead of claim 47, wherein the electrode feature penetrates by means of piercing.
 49. The lead of claim 47, wherein the electrode feature penetrates by means of resistance welding energy.
 50. The lead of claim 46, wherein the conductive fitting is inserted within the electrode feature.
 51. The lead of claim 46, wherein the elongate inner structure includes a lumen extending therethrough along a length of the structure.
 52. The lead of claim 51, further comprising a second elongate conductor extending within the lumen.
 53. The lead of claim 51, wherein the lumen is approximately coaxial with the outer surface of the elongate inner structure.
 54. The lead of claim 52, further comprising a distal tip electrode coupled to the second elongate conductor.
 55. The lead of claim 46, further comprising: a second electrode mounted about the outer insulative layer; and wherein the inner assembly further comprises a second elongate conductor extending along the outer surface of the elongate inner structure and a second conductive fitting coupled to the second elongate conductor; the outer insulative layer further includes a second opening in proximity to the second fitting; wherein the second electrode is coupled to the second fitting via the second opening.
 56. The lead of claim 55, wherein the elongate inner structure includes a lumen extending therethrough along a length of the structure.
 57. The lead of claim 56, further comprising a third elongate conductor extending within the lumen.
 58. The lead of claim 56, wherein the lumen is approximately coaxial with the outer surface of the elongate inner structure.
 59. The lead of claim 57, further comprising a distal tip electrode coupled to the third elongate conductor.
 60. A medical electrical lead, comprising: an inner assembly including an elongate inner structure, an elongate conductor extending along an outer surface of the elongate inner structure and a conductive fitting coupled to the elongate conductor; an outer insulative layer covering the inner assembly and including an opening in proximity to the fitting; and an electrode mounted about the outer insulative layer and coupled to the fitting via the opening; wherein the fitting conforms to a contour of the inner assembly.
 61. The lead of claim 60, wherein the fitting includes an inner surface conforming to an outer surface of the elongate inner structure.
 62. The lead of claim 60, wherein the fitting is flexible.
 63. The lead of claim 60, wherein the conductive fitting further includes a feature protruding outward through the opening for the coupling with the electrode.
 64. The lead of claim 60, wherein the elongate inner structure includes a lumen extending therethrough along a length of the structure.
 65. The lead of claim 64, further comprising a second elongate conductor extending within the lumen.
 66. The lead of claim 64, wherein the lumen is approximately coaxial with the outer surface of the elongate inner structure.
 67. The lead of claim 65, further comprising a distal tip electrode coupled to the second elongate conductor.
 68. The lead of claim 60, further comprising: a second electrode mounted about the outer insulative layer; and wherein the inner assembly further comprises a second elongate conductor extending along the outer surface of the elongate inner structure and a second conductive fitting coupled to the second elongate conductor; the outer insulative layer further includes a second opening in proximity to the second fitting; wherein the second electrode is coupled to the second fitting via the second opening.
 69. The lead of claim 60, wherein the elongate inner structure includes a lumen extending therethrough along a length of the structure.
 70. The lead of claim 69, further comprising a third elongate conductor extending within the lumen.
 71. The lead of claim 69, wherein the lumen is approximately coaxial with the outer surface of the elongate inner structure.
 72. The lead of claim 70, further comprising a distal tip electrode coupled to the third elongate conductor.
 73. A method for making an elongate medical device, the method comprising the steps of: coupling a conductive fitting to an elongate conductor; covering the elongate conductor and the conductive fitting coupled thereto with an insulative layer; and removing a portion of the insulative layer in proximity to the fitting.
 74. The method of claim 73, further comprising the steps of: positioning the elongate conductor along an elongate structure after covering the elongate conductor and the conductive fitting coupled thereto with an insulative layer; covering the elongate conductor and the elongate structure with a second insulative layer; and providing an opening through the second insulative layer in proximity to the fitting in order to expose the fitting.
 75. The method of claim 74, wherein the step of removing a portion of the insulative layer is accomplished in conjunction with providing the opening through the second insulative layer. 